The Smoke Shed Brewery (HERMS)

[aerostef]

Hi all,

I decided to build my new brewery largely based on Kal's "the electric brewery", with a few differences:
- Limited Budget
- Location (240V standard)
- I always brew outside (I live in a rented house)
- The electric circuit in my house is limited... (Will be using a 3kw element)
- I am using 12V variable speed pumps (solar project)

Despite all the points above, it is fairly easy to convert Kal's design to fit with my requirements.

The main differences are the relays. I am using standard Hager contactors that fit nicely on a DIN rail. Note the extra circuit breaker inside the panel:


More components in the control box


The front panel with tags


I started testing the panel and so far so good. The cabinet is grounded properly, the lights all work, relays/contactors seem to work fine. More on the control panel to come in a later post.

The kettle:

I resused some old SS pots that were in a mint condition. The copper pipes you see in the picture at the end of the valves have been replaced by "camlocks" SS quick connectors.


The coil I'm using is from a cornelius in-line cooler (MAXI310). Fits perfectly! Some of the fittings are brass... I will upgrade to SS one day, I promise!
You can also wee the 3kW heating element. I had no real issue with this type of element before, it just takes a little longer to come to the boil than a 5.5kW.


The mash tun:
Nothing too exciting here, appart from the grain filter. This cheap filter worked a treat on my older setup, so I have great hopes for this one.


More later...

[aerostef]

I finished testing the panel at the week end and everything works fine. Now I just need some more time and brew a beer!

Some more pics:

The connectors I use, all unsing EU standards



The brewery (just needs a proper house now around it)


The pump controller: 2 variable power supplies for the solar pumps


The finished controller

[Kev888]

Crikey, a great deal of loving care put into this one; very impressive!!

Whilst fairly clued up on many things electronic, I've recently ordered my first ever PID - partly because I think its something I should know about and want to play with! Can I ask, if the contactors are being used as an alternative to SSRs are they up to rapid switching, or are the PIDs just being used at a sedate speed?

Thanks
kev

[barneey]

Looks great, now to find me someone to build me a control panel

[aerostef]

I use solid state relays and contactors for this control panel. I wanted complete isolation just in case of SSR failure.
PIDs are great!

[Kev888]

Ah, I see, thanks.

I'd guess you've been brewing for a while to be concerned with this level of control, but for what its worth I hope the first brew goes well!!

Cheers
kev

[Deller12]

If i were you i get some PID's on the control panel Well built hope the 1st brew goes well

[Spud395]

That just confuses me, dont get me wrong it looks the job.

[aerostef]

Kev888: I wanted a HERMS brewery for consistency. And I love my gadgets

Deller12: I think I'll need a bigger control panel for version 2 to add even more PIDs
In fact on this project, only 2 PIDs are used as PIDs the 3rd one, taking the temperature of the MT, is only for monitoring purposes. The device on the right is just a timer/alarm.
The volt and amp meters are just there for added coolness

[Deller12]

Kev888: I wanted a HERMS brewery for consistency. And I love my gadgets

Deller12: I think I'll need a bigger control panel for version 2 to add even more PIDs

Lol you can never have too many PIDS

In fact on this project, only 2 PIDs are used as PIDs the 3rd one, taking the temperature of the MT, is only for monitoring purposes. The device on the right is just a timer/alarm.
The volt and amp meters are just there for added coolness

[beermonsta]

Crikey, a great deal of loving care put into this one; very impressive!!

Whilst fairly clued up on many things electronic, I've recently ordered my first ever PID - partly because I think its something I should know about and want to play with! Can I ask, if the contactors are being used as an alternative to SSRs are they up to rapid switching, or are the PIDs just being used at a sedate speed?

Thanks
kev

I use solid state relays and contactors for this control panel. I wanted complete isolation just in case of SSR failure.
PIDs are great!

[/quote]
1st of all ... great effort and high quality electronics - superb! - did you make the PCB's yourself? You must work with electronics for a job(I don't but I do love making similar stuff )
some questions and observations if you don't mind! - from the quote above are the "contactors" (I guess this is american for relay ) actually SSR's? or are there some SSR's hidden out of view? If so - I never knew you could get circuit breaker style DIN SSR's! - does the rail act as a heat sink as well?
Also You have used "EU standard" sockets but be aware that these don't seem to be the ones rated for high temperature. They would have a notch in them so that only a heat rated plug would fit them - a C15/C16 - see http://en.wikipedia.org/wiki/IEC_60320. This will allow a 120'C rather that 70'C temperature rating, important if you are using say 3000watts/13Amps of electrical heating for a single element.
Other than that I applaud you for such a fine effort. Well done that man!

[aerostef]

The PCBs (i assume you are talking about the pump speed controllers) are from conrad electronics. Fast and easy to assemble. Contactors and relays are the same yes... But the PIDs in my set up use SSR (will take a picture later). The relays/contactors are only used to:
1. Power the whole unit (didnt want 15A going through a switch)
2. Select either the boil element or the HLT element

There are no DIN SSR as far as i know, but that would be a good idea!

As for the connectors: i doubt they will ever reach anything above 30 degrees... They are only used on the control panel, at least 1.5m from the heat source.

[beermonsta]

Ah! I see - I think I now understand, your SSR's are with (near) the heat source and as such are independant (modular) of your control box. Hence the power connectors in your control box don''t need to handle high currents or loads. Brilliant!
So...are your SSR's in their own enclosures with their own independent power supplies - fed by a low current/voltage signal from your main control box?
Be nice to see a picture of the SSRs for a full picture!
Cheers
BM

[aerostef]

Here is a picture of the control panel showing the SSRs on top.
They are within the control panel, connected to a heat sink. They are controlled by the 12V source from the PIDs.

I plug the control panel to the main. The control panel then feeds current to the pumps and the 2 heating elements.
So the connectors do handle the 13Amps current. I will take more pictures with the whole set-up connected when I'll brew next.

[beermonsta]

Ah! NOW I see - I shouldn't guess things should I! I presumed from the first set of photos that show the top and bottom there wouldn't be room for the SSR's - I forgot about the sides

Thats a cracker of a box to build in - plenty of room for everything. I bet cutting out the holes drove you crazy! You mentioned the pump speed controllers are from conrad electronics...on the base (with the din rail and contactors there is also a transformer and two circuits there. Are they also from the same company, and are they providing power for the contactors (on the low power side from the PID units)?

Cheers,
BM